Multiaxial polyethylene fabric and laminate

Abstract

Provided is a multiaxial fabric comprising a first layer comprising a first layer comprising substantially parallel resin-free polyethylene yarns oriented in a first direction; a second layer comprising substantially parallel resin-free polyethylene oriented in a second direction, the first and second directions being skew with respect to each other; a layer, interposed between and in contact with each of the first and second layers, and comprising a thermoplastic or thermoset film; and a yarn interlaced transversely among each of the layers of the multiaxial fabric.

1. A multiaxial fabric comprising:
 a first layer comprising substantially parallel and substantially resin-free polyethylene yarns oriented in a first direction; 
 a second layer comprising substantially parallel and substantially resin-free polyethylene yarns oriented in a second direction, the first and second directions being skew with respect to each other; 
 a layer, interposed between and in contact with each of the first and second layers, and comprising a thermoplastic or thermoset film; and 
 a yarn interlaced transversely among each of the layers of the multiaxial fabric, wherein the fabric is coated with a high viscosity polymer that has a Tg in the range of −40 to 0° C., and a zero shear melt viscosity of 2×10 6  to 10 13  poise at 20° C.; 
 the yarns of the second layer are skew at an angle of 90° with respect to the yarns of the first layer; and 
 the polyethylene has a number averaged molecular weight of at least 1 million. 
 
     
     
       2. The fabric of  claim 1 , wherein the yarns of the second layer are skew at an angle of 90° with respect to the yarns of the first layer. 
     
     
       3. The fabric of  claim 1 , wherein the polyethylene has a number averaged molecular weight of at least 1 million. 
     
     
       4. The fabric of  claim 1 , wherein the thermoplastic or thermoset film comprises polyethylene. 
     
     
       5. The fabric of  claim 1 , comprising an additional layer, positioned as a backing layer, said layer comprising an aramid felt. 
     
     
       6. The fabric of  claim 5 , wherein the aramid felt comprises aramid staple fiber. 
     
     
       7. The fabric of  claim 5 , wherein the aramid felt comprises poly(p-phenylene terphthalamide) staple. 
     
     
       8. The fabric of  claim 1 , comprising an additional layer, positioned as a backing layer, said layer comprising polypyridobisimidazole. 
     
     
       9. The fabric of  claim 8  wherein polypyridobisimidazole is poly[2,6-diimidazo[4,5-b:4,5-e]-pyridinylene-1,4(2,5-dihydroxy)phenylene). 
     
     
       10. The fabric of  claim 1 , comprising an additional layer, positioned as a backing layer, said layer comprising an polyolefin felt. 
     
     
       11. The fabric of  claim 10 , wherein the polyolefin felt comprises polyolefin staple fiber. 
     
     
       12. The fabric of  claim 10 , wherein the polyolefin felt comprises polyethylene staple. 
     
     
       13. The fabric of  claim 1 , wherein the transverse yarn comprises polyethylene fiber. 
     
     
       14. The fabric of  claim 1 , additionally comprising one or more layers, said layers being constructed to provide alternating layers comprising (i) polyethylene yarns that are substantially resin-free and substantially parallel, wherein said further polyethylene yarns are skew to the yarns in each adjacent layer and (ii) thermoplastic or thermoset film. 
     
     
       15. The fabric of  claim 14 , comprising at least 10 layers of polyethylene yarns. 
     
     
       16. A garment comprising the fabric of  claim 1 . 
     
     
       17. An article comprising the fabric of  claim 1 . 
     
     
       18. A method of manufacturing a multiaxial fabric comprising:
 providing a thermoplastic or thermoset film; said film having a first and a second surface; 
 contacting a first layer comprising a plurality of substantially resin-free polyethylene yarns being substantially parallel in a first direction with the first surface of the film; 
 contacting a second layer comprising a plurality of substantially resin-free polyethylene yarns being substantially parallel in a second direction and skew or offset with respect to the polyethylene yarns of the first layer with the film, wherein the second layer contacts the film on the second surface of the film; and 
 transversely interlacing a transverse yarn within the multiaxial fabric, wherein: 
 the fabric is coated with a high viscosity polymer that has a Tg in the range of −40 to 0° C., and a zero shear melt viscosity of 2×10 6  to 10 13  poise at 20° C.; 
 the yarns of the second layer are skew at an angle of 90° with respect to the yarns of the first layer; and 
 the polyethylene has a number averaged molecular weight of at least 1 million.